System and method for exposed aggregate architectural coating for existing concrete structures

ABSTRACT

The invention involves an exposed aggregate architectural coating to be applied to existing concrete structures. The invention includes a method of preparing and roughening an existing concrete structure surface, mixing the components of the exposed aggregate architectural coating, applying the coating to the existing concrete structure, spreading the coating to a thickness of one-fourth of an inch or thinner, using a trowel, gauge rake, or other method to smoothen the coating, allowing the coating to cure, applying a surface retarder once the exposed aggregate architectural coating has stiffened, allowing the surface retarder to cure for twenty-four hours, and washing the surface with a pressure-washer to remove the surface retarder, then “acid-washing” the surface to remove residue and create a desired texture. The resulting applied exposed aggregate architectural coating will have an exposed aggregate finish that is durable and suitable for high vehicular and pedestrian traffic areas.

TECHNICAL FIELD OF THE INVENTION

The present disclosure relates generally to resurfacing existingconcrete structures, and more specifically, a system and method for anexposed aggregate architectural coating used to restore existingconcrete structures.

COPYRIGHT AND TRADEMARK NOTICE

A portion of the disclosure of this patent application may containmaterial that is subject to copyright protection. The owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightswhatsoever.

Certain marks referenced herein may be common law or registeredtrademarks of third parties affiliated or unaffiliated with theapplicant or the assignee. Use of these marks is by way of example andshould not be construed as descriptive or to limit the scope of thisinvention to material associated only with such marks.

BACKGROUND OF THE INVENTION

It is well known in the fields of construction and architecture thatconcrete can be utilized as a flooring and wall material for bothcommercial and residential purposes. The use of concrete flooring andwall structures in high traffic areas over a number of years results inworn-down, old concrete, with undesirable concrete finishes. Theconcrete flooring and wall material may still be structurally sound, butno longer aesthetically pleasing. As a solution, the concrete trade hasdeveloped multiple exposed aggregate concrete finishes in variouscolors, textures, and methods of application.

However, a drawback to these finishes is that the existingstructurally-sound concrete, plumbing, and electrical wiring typicallyneed to be demolished and removed, in order to install the new concretefinish. Moreover, installing new plumbing, electrical wiring, and fullminimum-depth exposed aggregate flooring, which is typically a minimumof four inches thick or greater, is labor-intensive, time-consuming, andexpensive.

Accordingly, there is an inadequately addressed need for anarchitectural coating that can be installed over the existingstructurally-sound concrete, and which will result in the desirable,aesthetically pleasing, exposed aggregate finish, without requiringdemolition or re-installation of any plumbing, electrical wiring, orother sound pre-existing structures. Such an architectural coating willresult in an exposed aggregate finish, and will be less time-consumingto install, while still being extremely durable and capable ofwithstanding rigorous pedestrian and vehicular traffic, even at athickness of less than one fourth of an inch.

Therefore, there is a need for a system and method for exposed aggregatearchitectural coating used to restore existing concrete structures,which addresses the above-mentioned concerns. It is to these ends thatthe present invention has been developed.

SUMMARY OF THE INVENTION

To minimize the limitations in the prior art, and to minimize otherlimitations that will become apparent upon reading and understanding thepresent specification, the present invention describes a system andmethod for applying an exposed aggregate architectural coating torestore existing concrete structures, the exposed aggregatearchitectural coating typically comprising a thin, durable, coatingmaterial applied to existing concrete structures that have beenroughened, or otherwise prepared, to preserve the integrity of thepre-existing concrete structures.

Generally, the invention involves implementation of an exposed aggregatearchitectural coating applied to existing concrete structures. Thepresent invention addresses and alleviates having to remove existingstructurally-sound concrete and sound infrastructure embedded in theconcrete. In accordance with the present invention, the exposedaggregate architectural coating is comprised of a modified,cement-based, two-part polymer. In some exemplary embodiments, theexposed aggregate architectural coating is thinner than standardconcrete finishing materials, which makes installation lesslabor-intensive and time-consuming, while still having the ability towithstand high vehicular and pedestrian traffic. In exemplaryembodiments, the architectural coating can be mixed with different typesof sand, such as silica sand, silica carbide, or other sand material, soas to present various colors and various exposed aggregates andbroadcasted materials.

A method for preparing and applying an exposed aggregate architecturalcoating, in accordance with some exemplary embodiments of the presentinvention, may include the steps of: preparing a first composition bycombining 41 to 50 percent sand with 50 to 59 percent cement; preparinga second composition by combining 75 to 86 percent water with 14 to 25percent glue combining the first composition with the second compositionto form an exposed aggregate architectural coating; preparing apre-existing cement structure to create a roughened surface having aconcrete surface profile of three or greater; and applying the exposedaggregate architectural coating to the roughened surface of thepre-existing cement structure, wherein the exposed aggregatearchitectural coating forms a thickness of between 1/32nd of an inch andone-fourth of an inch above the roughened surface.

A method for preparing and applying an exposed aggregate architecturalcoating to a flooring surface, in accordance with some exemplaryembodiments of the present invention, may include the steps of:preparing a first composition by combining 41 to 50 percent sand with 50to 59 percent cement; preparing a second composition by combining 75percent water with 25 percent glue; combining the first composition withthe second composition to form an exposed aggregate architecturalcoating; preparing a pre-existing cement structure to create a roughenedsurface having a concrete surface profile of three or greater; andapplying the exposed aggregate architectural coating to the roughenedsurface of the pre-existing cement structure, wherein the exposedaggregate architectural coating forms a thickness of between 1/32nd ofan inch and one-fourth of an inch.

A method for preparing and applying an exposed aggregate architecturalcoating to a wall surface, in accordance with some exemplary embodimentsof the present invention, may include the steps of: preparing a firstcomposition by combining 41 to 50 percent sand with 50 to 59 percentcement; preparing a second composition by combining 86 percent waterwith 14 percent glue; combining the first composition with the secondcomposition to form an exposed aggregate architectural coating;preparing a pre-existing cement structure to create a roughened surfacehaving a concrete surface profile of three or greater; and applying theexposed aggregate architectural coating to the roughened surface of thepre-existing cement structure, wherein the exposed aggregatearchitectural coating forms a thickness of between 1/32nd of an inch andone-eighth of an inch.

In some exemplary embodiments of the present invention, the existingstructurally-sound concrete substrate or surface on which thearchitectural coating will be applied will first need to be prepared tocreate a roughened surface for the subsequent application of the exposedaggregate architectural coating. The roughening of the existing surfacemay be achieved by grinding, shot-blasting and/or sandblasting. Inexemplary embodiments where the exposed aggregate architectural coatingwill be applied using a gauge raking method, any imperfections in theexisting concrete surface, such as cracks, dips, or holes, should alsobe repaired. Once the existing surface has been roughened and prepared,the architectural coating composition is applied to the roughenedsurface and spread over the surface such that the architectural coatingis one-fourth of an inch in thickness or less. The architectural coatingcan then be troweled, such as with a vibrating trowel. The surface ofthe architectural coating may then also be finish troweled, such as witha weighted trowel, to achieve still a smoother finish.

In some exemplary embodiments, a surface retarder may be applied to thearchitectural coating and left to cure and harden for approximatelytwenty-four hours. In other exemplary embodiments, as an alternative toapplying a surface retarder, chemical etching can instead be utilized tocreate a smoother, etched surface. After about twenty-four hours haveelapsed, the surface retarder may be washed away to expose the aggregatearchitectural coating. After yet another twenty-four hours have elapsed,any surface residue and laitance may also be removed by etching thesurface using detergents and etching chemicals, i.e. “acid-washing.”

An exposed aggregate architectural coating in accordance with someexemplary embodiments may be comprised of a modified, two-part polymer,cement-based architectural-topping and wall-coating material. Thearchitectural coating is used to resurface existing old, deterioratedconcrete, for the purpose of refreshing the concrete, and for theadditional purpose of enhancing the concrete finish, leaving the coatingwith a sanded or exposed aggregate finish. Additionally, thearchitectural coating may also be used to resurface new concrete, suchas to create a different aesthetic style, which process is still morecost effective and affordable than use of traditional concrete material.

The exposed aggregate architectural coating can have a visually stunningappearance, particularly if broadcasted with anyone-fourth inch orsmaller natural or plastic aggregate materials, including glass,seashells, or the like. The architectural coating will tenaciously bondto an existing substrate surface, such as a pre-existing concretesurface, concrete masonry unit, or the like. The architectural coatingmaterial is extremely durable and can withstand vehicular traffic withinseventy-two hours of being applied in accordance with exemplaryembodiments of the application method, and can withstand heavy foottraffic within twenty-four hours of application. The architecturalcoating is suitable for both floors and walls, and is long lasting,durable, and visually appealing, yet still having a thickness of lessthan one-fourth of an inch, thereby enhancing the ease of installation.The architectural coating may be as thin as 1/32nd of an inch, whilestill being extremely durable and suitable for pedestrian and vehiculartraffic for many years. Such a thin composition and application resultsin a much more cost-efficient and labor-efficient method for resurfacingconcrete than the present industry-standard techniques. Such a thincomposition also results in greater flexibility and cost-efficiency interms of design needs and decorative preferences.

The untreated architectural coating material has a color of white orgrey, thereby allowing the architectural coating material to beintegrally colored using cement pigment to any desired color, to meetany creative and decorative needs. When the coating is applied to athickness of one-fourth of an inch, the coating material can bebroadcasted with any one-fourth of an inch or smaller natural, plastic,or other aggregate material, such as for example glass, sea shells,tumbled porcelain, or other materials serving decorative purposes. Thethin composition of the exposed aggregate architectural coating reducesthe amount of aggregate material needed to accomplish the broadcastingeffect, thereby being more cost-efficient and labor-efficient.

The exposed aggregate architectural coating is intended to enhance theappearance of existing concrete in any location. The architecturalcoating is therefore suitable for both interior and exterior use, forboth flooring and wall surfaces, and for both residential or commercialhardscapes or parking structures, without need to restrict the dailyamount of traffic encountering the architectural coating.

The present invention therefore provides an exposed aggregatearchitectural coating for which installation does not require thedemolition and removal of the existing structurally-sound concretesurface and any plumbing, electrical wiring, or other structures withinthe existing surface. In exemplary embodiments, the exposed aggregatearchitectural coating should not overload the weight capacity of theexisting flooring or surface on which the architectural coating isapplied. In exemplary embodiments, the exposed aggregate architecturalcoating is thinner than typical concrete finishing materials, whichshould result in installation being more cost-efficient and lesslabor-intensive and time-consuming, but which coating is highly durableand capable of withstanding high vehicular and pedestrian traffic.

BRIEF DESCRIPTION OF THE DRAWINGS

The system and the method for exposed aggregate architectural coating asdisclosed herein are further described in terms of exemplaryembodiments. These embodiments are described in detail with reference tothe drawings, which have not necessarily been drawn to scale, in orderto enhance their clarity and improve understanding of the variousembodiments of the invention. Furthermore, elements that are known to becommon and well understood to those in the industry are not depicted inorder to provide a clear view of the various embodiments of theinvention. These embodiments are non-limiting exemplary embodiments, inwhich like reference numerals represent similar structures throughoutthe several views of the drawings. The drawings that accompany thedetailed description can be briefly described as follows:

FIG. 1A illustrates a perspective and partial cross-sectional view of anarchitectural coating in accordance with exemplary embodiments of thepresent invention.

FIG. 1B illustrates a perspective view of an architectural coating inaccordance with exemplary embodiments of the present invention.

FIG. 2A illustrates a side cross-sectional close-up view of thearchitectural coating depicted in FIG. 1A.

FIG. 2B illustrates a side cross-sectional close-up view of thearchitectural coating depicted in FIG. 1B.

FIG. 3A illustrates a cross-sectional view of an exposed aggregatearchitectural coating applied over a roughened surface of an existingconcrete structure, in accordance with the practice of exemplaryembodiments of the present invention.

FIG. 3B illustrates a perspective cross-sectional view of a roughenedsurface of an existing concrete structure.

FIG. 4 depicts a block diagram of an overview of a process utilized forapplying an exposed aggregate architectural coating, in accordance withthe practice of exemplary embodiments of the present invention.

FIG. 5A-FIG. 5B depict tables listing ingredients for exposed aggregatearchitectural coatings, in their respective amounts and proportions, forcompositions in accordance with exemplary embodiments of the presentinvention.

FIG. 6 illustrates a block diagram of the process utilized for preparingand roughening the pre-existing concrete structure surface.

FIG. 7 depicts a block diagram of the process utilized for preparing theexposed aggregate architectural coating composition.

FIG. 8 depicts a block diagram of the detailed process utilized forapplying the exposed aggregate architectural coating to a flooringstructure.

FIG. 9 illustrates a block diagram of the detailed process utilized forapplying the exposed aggregate architectural coating to a wallstructure.

DETAILED DESCRIPTION OF THE INVENTION

In the following discussion that addresses a number of embodiments andapplications of the present invention, reference is made to theaccompanying drawings that form a part thereof, where depictions aremade, by way of illustration, of specific embodiments in which theinvention may be practiced. It is to be understood that otherembodiments may be utilized, and changes may be made without departingfrom the scope of the invention. Wherever possible, the same referencenumbers are used in the drawings and the following description to referto the same or similar elements.

In the following detailed description, numerous specific details are setforth by way of example in order to provide a thorough understanding ofthe relevant teachings. However, it should be apparent to those skilledin the art that the present teachings may be practiced without suchdetails. In other instances, well known structures, components and/orfunctional or structural relationships thereof, etc., have beendescribed at a relatively high-level, without detail, in order to avoidunnecessarily obscuring aspects of the present teachings.

Throughout the specification and claims, terms may have nuanced meaningssuggested or implied in context beyond an explicitly stated meaning.Likewise, the phrase “in one embodiment/example” as used herein does notnecessarily refer to the same embodiment and the phrase “in anotherembodiment/example” as used herein does not necessarily refer to adifferent embodiment. It is intended, for example, that claimed subjectmatter include combinations of example embodiments in whole or in part.

Conditional language used herein, such as, among others, “can,” “could,”“might,” “may,” “e.g.,” and the like, unless specifically statedotherwise, or otherwise understood within the context as used, isgenerally intended to convey that certain embodiments include, whileother embodiments do not include, certain features, elements and/orsteps. Thus, such conditional language is not generally intended toimply that features, elements and or steps are in any way required forone or more embodiments, whether these features, elements and/or stepsare included or are to be performed in any particular embodiment.

The terms “comprising,” “including,” “having,” and the like aresynonymous and are used inclusively, in an open-ended fashion, and donot exclude additional elements, features, acts, operations and soforth. Also, the term “or” is used in its inclusive sense (and not inits exclusive sense) so that when used, for example, to connect a listof elements, the term “or” means one, some, or all of the elements inthe list. Conjunctive language such as the phrase “at least one of X, Y,and Z,” unless specifically stated otherwise, is otherwise understoodwith the context as used in general to convey that an item, term, etc.may be either X, Y, or Z. Thus, such conjunctive language is notgenerally intended to imply that certain embodiments require at leastone of X, at least one of Y, and at least one of Z to each be present.The term “and or” means that “and” applies to some embodiments and “or”applies to some embodiments. Thus, A, B, and or C can be replaced withA, B, and C written in one sentence and A, B, or C written in anothersentence. A, B, and or C means that some embodiments can include A andB, some embodiments can include A and C, some embodiments can include Band C, some embodiments can only include A, some embodiments can includeonly B, some embodiments can include only C, and some embodimentsinclude A, B, and C. The term “and or” is used to avoid unnecessaryredundancy. Similarly, terms, such as “a, an,” or “the,” again, may beunderstood to convey a singular usage or to convey a plural usage,depending at least in part upon context. In addition, the term “basedon” may be understood as not necessarily intended to convey an exclusiveset of factors and may, instead, allow for existence of additionalfactors not necessarily expressly described, again, depending at leastin part on context.

While exemplary embodiments of the disclosure may be described,modifications, adaptations, and other implementations are possible. Forexample, substitutions, additions, or modifications may be made to theelements illustrated in the drawings, and the methods described hereinmay be modified by substituting, reordering, or adding stages to thedisclosed methods. Thus, nothing in the foregoing description isintended to imply that any particular feature, characteristic, step,module, or block is necessary or indispensable. Indeed, the novelmethods and systems described herein may be embodied in a variety ofother forms; furthermore, various omissions, substitutions, and changesin the form of the methods and systems described herein may be madewithout departing from the spirit of the invention or inventionsdisclosed herein. Accordingly, the following detailed description doesnot limit the disclosure. Instead, the proper scope of the disclosure isdefined by the appended claims.

The present disclosure relates to, among other things, a system andmethod for exposed aggregate architectural coating for existing concretestructures. Exemplary embodiments of the present disclosure aredescribed with reference to the drawings for illustration purposes andare not intended to limit the scope of the present disclosure.

Turning now to the figures, FIG. 1A and FIG. 1B illustrate partialcross-sectional views of exposed aggregate architectural coatings inaccordance with exemplary embodiments of the present invention. Inexemplary embodiments, the architectural coating 100 can be applied atvarious thicknesses, typically not greater than one-fourth of an inchbut may also be applied in a thickness of up to one-half of an inch orgreater, such as a thickness of 1/32nd of an inch, one-sixteenth of aninch, one-eighth of an inch, and up to one-fourth of an inch or greater,as a layer on top of a pre-existing concrete structure, for example,pre-existing concrete structure 200.

As may be appreciated from the view of FIG. 1A, in exemplaryembodiments, the exposed aggregate architectural coating 100 may begenerally applied to a pre-existing concrete structure 200 having asurface that has been previously prepared by, for example, rougheningthe surface as will be discussed further below. Generally, aggregatearchitectural coating 100 is comprised of a modified, two-part polymer,cement-based architectural-topping and or wall-coating material. FIG. 1Billustrates one exemplary embodiment of the architectural coating 100,which is thicker than the embodiment of FIG. 1A, and thus allows forbroadcasting to be applied thereto. In either case, as will be discussedin greater detail below, the architectural aggregate 100 is applied ontop of pre-existing concrete structure 200—typically once pre-existingconcrete structure 200 has been prepared by, for example, creating aroughened surface having a suitable concrete surface profile as will beexplained further with reference to FIG. 3B below.

The architectural coating 100 is used to resurface existing old,deteriorated concrete structure 200, for the purpose of refreshing theconcrete structure 200, and for the additional purpose of enhancing theconcrete finish of concrete structure 200, wherein the coating 100 has asanded or exposed aggregate finish. Additionally, the architecturalcoating 100 may also be used to resurface new concrete, such as tocreate a different aesthetic style, which process is still more costeffective and affordable than use of traditional concrete material.

The exposed aggregate architectural coating 100 can have a visuallystunning appearance, particularly if broadcasted with any one-fourthinch or smaller natural or plastic aggregate materials, including glass,sea shells, or the like. The architectural coating 100 will tenaciouslybond to an existing substrate surface, such as the surface ofpre-existing concrete structure 200. The architectural coating material100 is extremely durable and can withstand vehicular traffic withinseventy-two hours of being applied, and can withstand heavy foot trafficwithin twenty-four hours of application. The architectural coating 100is suitable for both floors and walls, and is long lasting, durable, andvisually appealing, yet still having a thickness of not greater than oneinch, thereby enhancing the ease of installation.

In exemplary embodiments, the untreated architectural coating materialhas a color of white or grey, thereby allowing the architectural coatingmaterial to be integrally colored using cement pigment to any desiredcolor, to meet any creative and decorative needs of architecturalcoating 100. This coloring is advantageous over other materials forcement surfacing known to those skilled in the art, because white cementis typically more expensive to purchase and apply, particularly whenpoured to the industry-standard thickness of a minimum of four inches.Therefore, according to an exemplary embodiment of application of theexposed aggregate architectural coating of this invention, a whiteand/or light-colored wall or flooring surface can be more easily andcost-efficiently created, because the architectural coating layerapplied typically has a thickness of less than only one-fourth of aninch.

As such, controlling the thickness and color of an architecturalaggregate coating in accordance with the present invention may yield avariety of structurally protective, yet aesthetically appealing coatingsfor pre-existing concrete structures. For example, and in no waylimiting the scope of the present invention, FIG. 2A illustrates a sidecross-sectional close-up view of the architectural coating depicted inFIG. 1A, and FIG. 2B illustrates a side cross-sectional close-up view ofthe architectural coating depicted in FIG. 1B. These two close-up viewsshow how a thinner version may exclude broadcasting, while a thin butslightly thicker version may include broadcasting.

As may be appreciated from FIG. 2B, when architectural coating 100 isapplied to a thickness of at least one-fourth of an inch, thearchitectural coating 100 can be broadcasted with broadcastingaggregates 101 including but not limited to any one-fourth of an inch orsmaller natural or plastic aggregate, such as for example glass or seashells. The exposed aggregate architectural coating 100 is intended toenhance the appearance of existing concrete structures in any location,such as in exemplary embodiments, existing concrete structure 200. Thearchitectural coating 100 is therefore suitable for both interior andexterior use, on residential or commercial hardscapes or parkingstructures, without need to restrict the amount of traffic encounteringthe architectural coating.

In exemplary embodiments, the exposed aggregate architectural coatingmaterial to create or form architectural coating 100 can be prepackaged,such as a prepackaged fifty-pound (50 lbs.) “Part A” mixture containingsand and cement, and a prepackaged five-quart (5 qts.) “Part B” mixturecontaining glue and water, so as to allow for an easy mixing of theingredients that comprise the coating composition, which compositionresults in an aesthetically pleasing sand finish. The architecturalcoating 100 has the flexibility to contain broadcasting aggregates 101and thus configured to receive the broadcasting of any sand, glass, seashells, or other such materials into the architectural coating, therebycreating visually appealing surfaces. In some exemplary embodiments, thearchitectural coating 100 composition can be prepared in such a way soas to create custom sand blends and material blends in any creativemanner to create various surface material compositions, resulting indifferent appearances and styles. In some exemplary embodiments, theaggregate architectural coating 100 composition can also be preparedwith recycled plastic and recycled glass aggregates, in order to promotegreen building practices.

Turning now to the next figure, FIG. 3A illustrates a perspectivecross-sectional view of the exposed aggregate architectural coating 100applied over a roughened surface 300 of existing concrete structure 200.As may be appreciated in FIG. 3A, the architectural coating 100 is muchthinner than the underlying pre-existing concrete structure 200. In oneexemplary embodiment of the present invention, the architectural coating100 when applied does not exceed a thickness of one-fourth of an inch.In another exemplary embodiment, the architectural coating 100 whenapplied, such as using the screeding method of application, may have athickness of up to one-half of an inch. The architectural coating 100 isgenerally a thin aggregate layer applied over an existing concretestructure roughened surface 300; however, because of the particularcomposition of ingredients of which the aggregate architectural coatingis comprised, as is more fully described below, architectural coating100 forms a very durable and strong material, capable of withstandingheavy vehicular and pedestrian traffic for many years. The durable yetthin architectural coating 100, therefore, allows for the resurfacing ofan existing, sound concrete structure 200, while alleviating the needfor demolition of the much larger existing, sound concrete structure 200and its internal structures in order to install a new concrete structureand surface having the industry-standard thickness, which is typicallyfour inches or greater.

FIG. 3B illustrates a perspective cross-sectional view of the initialstep in carrying out a method of the present invention according to anexemplary embodiment, comprising the preparation of the surface 300 ofthe pre-existing structurally-sound concrete structure 200.

Application of the exposed aggregate architectural coating necessitatespreparation of the existing concrete surface 300. In an exemplaryembodiment, the existing concrete structure 200 to be coated shouldinitially be structurally sound. In an exemplary embodiment, this maynecessitate that an existing surface 300 of concrete structure 200having any damage should first be properly patched or repaired, such aswhere the exposed aggregate architectural coating will be applied usinga gauge raking method (conversely, if the exposed aggregatearchitectural coating is being applied using the screeding method,pre-existing concrete structure surface damage may not have to berepaired). In yet another embodiment, this may necessitate that anycracks in the surface 300 be repaired. In yet another exemplaryembodiment, any holes or pits in the structure 200 or concrete structuresurface 300 should be filled, such as where the exposed aggregatearchitectural coating will be applied using a gauge raking method.Typically, in exemplary embodiments, all existing control joints andexpansion joints in the existing surface 300 and concrete structure 200should be respected and not damaged or compromised when roughening theconcrete structure surface 300.

FIG. 4 depicts a block diagram of an overview of the process utilizedfor applying an exposed aggregate architectural coating in accordancewith some exemplary embodiments of the present invention. Morespecifically, FIG. 4 depicts method 400 for applying an exposedaggregate architectural coating. Although method 400 is exemplarilyshown with a series of steps in one particular sequence, method 400 mayinclude fewer or more steps in alternative sequences without deviatingfrom the scope of the present invention. As will be described in greaterdetail below, the process of applying the exposed aggregatearchitectural coating includes steps 401-408.

In step 401, the user should first prepare and roughen the existingconcrete surface. In an exemplary embodiment, this will include removingdebris and foreign surface material. In another exemplary embodiment,this will include repairing cracks, dips, holes, or other imperfectionsin the existing concrete structure, such as where the gauge rakingmethod will be used to apply the exposed aggregate architecturalcoating. (In exemplary embodiments where the screeding method ofapplication is used, “low spots” and other imperfections may not requirerepair before the exposed aggregate architectural coating may beapplied, however, cracks do need to be repaired.) In step 401, the usershould also roughen the surface of the pre-existing concrete structure.In an exemplary embodiment, this can be achieved by grinding thesurface, or in another exemplary embodiment, by sand-blasting,shot-blasting, or any other suitable method of roughening a concretesurface.

In step 402, the user may prepare the exposed aggregate architecturalcoating composition by combining the specified ingredients in theappropriate proportions as described more fully below in FIGS. 5A and5B, and in FIG. 7. This step may include mixing sand, such as silicasand or other sand material, and cement to form a “Part A” composition,then separately mixing glue and water to form a “Part B” composition,and then mixing both Part A and Part B together to form the materialwhich will comprise the exposed aggregate architectural coating to beapplied to a pre-existing concrete structure surface.

In step 403, the composition may be poured onto the roughened surface.In step 404, the coating composition may be spread to a desiredthickness on the pre-existing concrete structure surface using asqueegee, a gauge raking technique, a screeding and/or roddingtechnique, or other suitable techniques. In an exemplary embodimentwhere the coating is being applied to a wall structure as opposed to aflooring structure, it may be desirable to use the spray method to applythe coating, for ease of application and in order to create a consistentsurface thickness.

In step 405, if the exposed aggregate architectural coating is beingapplied to a flooring surface, the coated surface may be troweled usinga trowel such as a “Fresno” trowel, a vibrating trowel, and/or weightedtrowel. In an exemplary embodiment, this step may include using avibrating trowel to create a smooth and uniform surface texture of theexposed aggregate architectural coating. In another exemplaryembodiment, this step may include also using a weighted trowel to createa still smoother finish.

In step 406, after all trowel marks have been removed from the appliedexposed aggregate architectural coating such that the applied coatinghas a smooth surface, a surface retarder may be applied. The surfaceretarder may be allowed to cure for twenty-four hours before beingremoved. However, in other exemplary embodiments, the user may choosenot to apply a surface retarder, in order to create a smoother finish.Where a surface retarder has not been applied, or where a surfaceretarder was applied but did not achieve the desired surface texture,the user may wish to employ an “acid-washing” technique, to etch areaswhere the surface retarder did not perform well or to create a smootheretched finish, using etching material and/or detergents. Therefore, inexemplary embodiments, the user may employ the “acid-washing” techniqueto create a desired finish texture, and in other embodiments, the usermay also employ an etching technique to create a desired finish texture.

In step 407, after the surface retarder has cured for twenty-four hours,the newly coated surface may then be pressure-washed such that thesurface retarder is removed. In exemplary embodiments, the user mayensure that the surface retarder is fully removed from the exposedaggregate architecturally coated surface. In step 408, the user may use“acid-washing” on the coated surface to remove cement residue andlaitance.

Turning now to FIG. 5A and FIG. 5B, tables are provided to more easilyoutline the ingredients comprising the exposed aggregate architecturalcoating, in their respective amounts and proportions. The exposedaggregate architectural coating is comprised of two parts: Part A, whichcontains a proportion of sand, such as silica sand or other sandmaterial, and a proportion of cement; and Part B, which contains aproportion of glue, and a proportion of water. The amount of ingredientscomprising each part will depend upon the surface to be coated, whetherthe surface is a floor or wall surface. The amount of ingredients willalso be dependent upon the desired coating thickness, whether less thanone-eighth of an inch, one-eighth, or one-fourth.

With respect to Part A, various types of sand may be combined to form asingle exposed aggregate architectural surface coating. For example, inexemplary embodiments, types of sand of a particular coarseness and/orcolor may be combined. Combining multiple types of sand can createvarious desired textures, finishes, and appearances. In exemplaryembodiments where the user desires to create a coating having less thanone-eighth of an inch in thickness, a sand material should not exceed acoarseness of United States Sieve Size No. 20, which has a size of 0.841millimeters; otherwise, achieving the desired thickness will typicallynot be possible. In other exemplary embodiments where the user desiresto create a coating having one-eighth of an inch in thickness and up toone-fourth of an inch in thickness, a sand material should not exceed acoarseness of United States Sieve Size No. 16, which has a size of 1.19millimeters; otherwise, achieving the desired thickness will typicallynot be possible. Aggregate materials of up to one-fourth of an inch inthickness can be broadcasted onto the surface of the exposed aggregatearchitectural coating.

As depicted in FIG. 5A, in exemplary embodiments where the user isseeking to coat a flooring surface wherein the coating will have athickness of less than one-eighth of an inch, Part A will comprise aratio of 14 parts sand to 16 parts cement, wherein a “part” may be anyuniform measuring unit, such as pounds (lbs.) or quarts, depending uponthe measurements of the surface area to be coated. In other words, thePart A composition will comprise a ratio of 7:8 sand to cement. However,also in exemplary embodiments where the user is seeking a coating havinga thickness of less than one-eighth of an inch, Part A alternatively maycomprise an amount of sand of up to 16 parts; therefore, in suchembodiments, the ratio of sand to cement could be 16 parts sand to 16parts cement, i.e. a ratio of 1:1. Therefore, the Part A composition maycomprise an amount of sand within the range of 47 to 50 percent, and maycomprise an amount of cement within the range of 50 to 53 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a flooring surface wherein the coating will have athickness of less than one-eighth of an inch, Part B will comprise aratio of three parts water to one part glue, i.e. the Part B compositionwill comprise 75 percent water and 25 percent glue. One exemplaryembodiment of the application method to create a thickness of less thanone-eighth of an inch is by use of a squeegee.

In yet another exemplary embodiment where the user is seeking to coat aflooring surface wherein the coating will have a thickness of one-eighthof an inch, Part A will comprise a ratio of 14 parts sand to 16 partscement, i.e. a ratio of 7:8 sand to cement. However, also in exemplaryembodiments where the user is seeking a coating having a thickness ofone-eighth of an inch, Part A alternatively may comprise an amount ofsand of up to 16 parts; therefore, in such embodiments, the ratio ofsand to cement could be 16 parts sand to 16 parts cement, i.e. a ratioof 1:1 sand to cement. Therefore, the Part A composition may comprise anamount of sand within the range of 47 to 50 percent, and may comprise anamount of cement within the range of 50 to 53 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a flooring surface wherein the coating will have athickness of one-eighth of an inch, Part B will comprise a ratio ofthree parts water to one part glue, i.e. the Part B composition willcomprise 75 percent water and 25 percent glue. Multiple applicationmethods may be employed to create a thickness of one-eighth of an inch,such as by use of a gauge rake, and/or by screeding, and/or rodding, andany other suitable methods of application.

In yet another exemplary embodiment where the user is seeking to coat aflooring surface wherein the coating will have a thickness of one-fourthof an inch, Part A will comprise a ratio of 14 parts sand to 20 partscement. However, also in exemplary embodiments where the user is seekinga coating having a thickness of one-fourth of an inch, Part Aalternatively may comprise an amount of sand of up to 22 parts, and maycomprise an amount of cement of up to 28 parts; therefore, in suchembodiments, the ratio of sand to cement could be between 14 parts sandto 20 parts cement, and 22 parts sand to 28 parts cement, i.e. betweenthe reduced ratios of 7:10 sand to cement, and 11:14 sand to cement.Therefore, the Part A composition may comprise an amount of sand withinthe range of 41 to 44 percent, and may comprise an amount of cementwithin the range of 56 to 59 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a flooring surface wherein the coating will have athickness of one-fourth of an inch, Part B will comprise a ratio ofthree parts water to one part glue, i.e. the Part B composition willcomprise 75 percent water and 25 percent glue. Multiple applicationmethods may be employed to create a thickness of one-fourth of an inch,such as by use of a gauge rake, and/or by screeding, and/or rodding, orany other suitable methods of application.

As depicted in FIG. 5B, in exemplary embodiments where the user isseeking to coat a wall surface wherein the coating will have a thicknessof less than one-eighth of an inch, Part A will comprise a ratio of 14parts sand to 16 parts cement, wherein a “part” may be any uniformmeasuring unit, such as pounds (lbs.) or quarts, depending upon themeasurements of the surface area to be coated. In other words, the PartA composition will comprise a ratio of 7:8 sand to cement. However, alsoin exemplary embodiments where the user is seeking a coating having athickness of less than one-eighth of an inch, Part A alternatively maycomprise an amount of sand of up to 16 parts; therefore, in suchembodiments, the ratio of sand to cement could be 16 parts sand to 16parts cement, i.e. a ratio of 1:1. Therefore, the Part A composition maycomprise an amount of sand within the range of 47 to 50 percent, and maycomprise an amount of cement within the range of 50 to 53 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a wall surface wherein the coating will have a thicknessof less than one-eighth of an inch, Part B will comprise a ratio of sixparts water to one part glue, i.e. the Part B composition will compriseapproximately 86 percent water and 14 percent glue.

Where the user desires to create a wall coating having less thanone-eighth of an inch in thickness, a sand material should not exceed acoarseness of United States Sieve Size No. 20, which has a size of 0.841millimeters; otherwise, achieving the desired thickness will typicallynot be possible. In other exemplary embodiments where the user desiresto create a coating having one-eighth of an inch in thickness and up toone-fourth of an inch in thickness, a sand material should not exceed acoarseness of United States Sieve Size No. 16, which has a size of 1.19millimeters; otherwise, achieving the desired thickness will typicallynot be possible. Aggregate materials of up to one-fourth of an inch inthickness can be broadcasted onto the surface of the exposed aggregatearchitectural coating.

In an exemplary embodiment, application of the exposed aggregatearchitectural coating to a wall surface could be achieved by sprayingthe coating material onto the wall surface. Such a method may bedesirable so that the coating is applied in a uniform consistencythroughout the wall surface, which consistency may be more easilyachieved by the spray method. A float method can also be used inaddition to the spray method, in order to create an entirely flatconsistency of coating upon a wall surface.

In exemplary embodiments where the user is seeking to coat a wallsurface wherein the coating will have a thickness of one-eighth of aninch, Part A will comprise a ratio of 14 parts sand to 16 parts cement.In other words, the Part A composition will comprise a ratio of 7:8 sandto cement. However, also in exemplary embodiments where the user isseeking a coating having a thickness of one-eighth of an inch, Part Aalternatively may comprise an amount of sand of up to 16 parts;therefore, in such embodiments, the ratio of sand to cement could be 16parts sand to 16 parts cement, i.e. a ratio of 1:1. Therefore, the PartA composition may comprise an amount of sand within the range of 47 to50 percent, and may comprise an amount of cement within the range of 50to 53 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a wall surface wherein the coating will have a thicknessof one-eighth of an inch, Part B will comprise a ratio of six partswater to one part glue, i.e. the Part B composition will compriseapproximately 86 percent water and 14 percent glue. In an exemplaryembodiment where the user is seeking to coat a wall surface wherein thecoating will have a thickness of one-eighth of an inch, application ofthe exposed aggregate architectural coating to a wall surface could beachieved by spraying the coating material onto the wall surface, inorder to more easily achieve a uniform consistency throughout the wallsurface. A float method can also be used in addition to the spraymethod, in order to create an entirely flat consistency of coating upona wall surface.

Application of the exposed aggregate architectural coating to a wallsurface typically will not exceed a thickness of one-eighth of an inch,due to the weight of the material. However, in exemplary embodimentswhere the user is seeking to coat a wall surface wherein the coatingwill have a thickness of one-fourth of an inch, Part A will comprise aratio of 14 parts sand to 20 parts cement. Also in exemplary embodimentswhere the user is seeking a wall coating having a thickness ofone-fourth of an inch, Part A alternatively may comprise an amount ofsand of up to 22 parts, and may comprise an amount of cement of up to 28parts; therefore, in such embodiments, the ratio of sand to cement couldbe between 14 parts sand to 20 parts cement, and 22 parts sand to 28parts cement, i.e. between the ratios of 7:10 sand to cement, and 11:14sand to cement. Therefore, the Part A composition may comprise an amountof sand within the range of 41 to 44 percent, and may comprise an amountof cement within the range of 56 to 59 percent.

Turning now to Part B, in exemplary embodiments where the user isseeking to coat a wall surface wherein the coating will have a thicknessof one-fourth of an inch, Part B will comprise a ratio of six partswater to one part glue, i.e. the Part B composition will compriseapproximately 86 percent water and 14 percent glue.

As is described more fully below, Part A and Part B will be combined andmixed together to form the exposed aggregate architectural coating,which will be applied over an existing concrete structure surface.

Cement surfacing compositions typically contain a ratio of three partssand to one part cement (ratio of 3:1 sand to cement). However, in anexemplary embodiment of the present invention, the ratio of sand tocement is greatly modified, such that there is a much greater amount ofcement than in typical industry-standard compositions. In the presentinvention, exemplary embodiments typically will contain a ratio of 14parts sand to 16 parts cement, or 14 parts sand to 20 parts cement, or16 parts sand to 16 parts cement.

An exemplary embodiment will employ use of a very strong and durableglue material, such as “S-1100 Liquid Concentrate” polymer glue, in thePart B component. For this reason, a greater amount of cement is capableof being utilized in the Part A component, as compared theabove-described, industry-standard cement coating compositions having aratio of 3:1 sand to cement. The resultant exposed aggregatearchitectural coating is therefore extremely durable and capable ofwithstanding high amounts of pedestrian and vehicular traffic for manyyears, while having a thickness of only one-fourth of an inch or less,as compared to the industry standard cement surfaces and structuresrequiring a thickness of at least four inches.

Such a composition results in an unexpectedly durable and strongcement-based coating material, capable of withstanding heavy vehicularand pedestrian traffic for many years, while still having a thickness ofonly one-fourth of an inch or less, as opposed to the industry standardfour-inch or greater thickness for cement-based coatings. The durableyet thin exposed aggregate architectural coating of the presentinvention, therefore, allows for the resurfacing of an existing, soundconcrete structure, while alleviating the need for demolition of theexisting, sound concrete structure and its internal structures in orderto install a new concrete structure and surface having theindustry-standard thickness of four inches or greater.

The reduced thickness of the present invention also allows for areduction in the cost of manufacture and application of the coatingmaterial, and a reduction in the effort required to be expended in theapplication of the coating material. Additionally, the reduced thicknessof the present invention as opposed to industry-standard cementsurfacing allows for greater flexibility in decorative and designchoices: as described above, white cement which is typically expensivecan be much more liberally employed with the present invention. Also, aswill be described more fully below in FIG. 8, the broadcasting processof creating surface designs having exposed materials such as glass, seashells, and other decorative materials, is much more simplified, andwaste of broadcasted material is greatly reduced.

With reference to FIG. 6, the initial step in carrying out the method ofthe present invention according to an exemplary embodiment is depicted.More specifically, FIG. 6 depicts method 600 for preparing androughening an existing concrete structure surface. Although method 600is exemplarily shown with a series of steps in one particular sequence,method 600 may include fewer or more steps in alternative sequenceswithout deviating from the scope of the present invention. As will bedescribed in greater detail below, the process of applying the exposedaggregate architectural coating includes steps 601-607.

Method 600 for preparing and roughening the existing concrete surfacedepicts the process for the preparation of the surface of thepre-existing structurally-sound concrete structure. Installation of theexposed aggregate architectural coating necessitates preparation of theexisting concrete structure surface. The existing concrete structure tobe coated should initially be structurally sound. This may requirecarrying out step 601, that an existing concrete structure surfacehaving any damage should first be properly patched, and any cracks inthe surface should be repaired. Step 602 may require that any holes,dips, pits, or uneven surface texture areas in the underlying concretestructure or its surface should be filled and/or repaired, such as wherethe gauge raking method will be used to apply the exposed aggregatearchitectural coating (alternatively, in embodiments where the screedingmethod will be utilized to apply the exposed aggregate architecturalcoating, then holes, dips, pits, or other uneven surface texture areasdo not first need to be repaired). Step 603 may require that allexisting control joints, expansion joints, and any wiring, plumbing, orother structures in the existing surface and underlying concretestructure to be respected and not damaged or compromised when rougheningand preparing the concrete structure surface.

To prepare the surface of the pre-existing concrete structure forapplication of the exposed aggregate architectural coating, step 604would require that a roughened surface texture in the pre-existingconcrete structure surface be created, by use of a number of differentsurface-preparation techniques. In exemplary embodiments, the roughenedsurface texture can be created by grinding the pre-existing concretestructure surface. In another exemplary embodiment, the roughening canbe created by sandblasting. In yet another exemplary embodiment, theroughening can be created by using the “acid-washing” technique, whichemploys etching material and/or detergents. In yet another exemplaryembodiment, the roughening can be created by chemically etching andshot-blasting of the pre-existing concrete structure surface. Othersuitable techniques may also be used to create a roughened surfacetexture in the concrete structure surface.

In an exemplary embodiment, step 605 may be carried out, which wouldrequire that the existing concrete structure surface be mechanicallyprepared to a concrete surface profile (“CSP”) of three or greater, inorder to ensure that any surface contaminants are removed before thearchitectural coating is applied. In another exemplary embodiment, step606 may be carried out, which would require that any pre-existingcoatings, curing compounds, sealers, oil, or any bond-breakerspreviously applied to the existing concrete surface to first be removedin preparation for application of the architectural coating. Suchpre-existing materials may be removed by pressure-washing, the“acid-washing” technique employing etching material and/or detergents,or other suitable method.

In exemplary embodiments, step 607 may be carried out, wherein the usermay also ensure to thoroughly remove dust or other debris from theconcrete surface area to be coated, such as by vacuuming, sweeping, orpressure-washing, or other suitable method for removing unwantedparticles from a cement surface. In an exemplary embodiment, preparationof the concrete surface necessitates that the surface is cleaned, withany loose debris being removed from the roughened surface. It is anadvantage of the present invention that, due to the composition of theexposed aggregate architectural coating material, a primer is not neededto be applied to the pre-existing concrete structure surface before theexposed aggregate architectural coating can be applied.

FIG. 7 illustrates the process for preparing the exposed aggregatearchitectural coating composition. FIG. 7 depicts method 700 forpreparing the exposed aggregate architectural coating composition.Although method 700 is exemplarily shown with a series of steps in oneparticular sequence, method 700 may include fewer or more steps inalternative sequences without deviating from the scope of the presentinvention. As will be described in greater detail below, the process ofapplying the exposed aggregate architectural coating includes steps701-704.

To prepare the exposed aggregate architectural coating composition thatwill be applied to an existing surface to form the exposed aggregatearchitectural coating, a two-part composition comprised of “Part A” and“Part B,” having the ingredients and proportions described above inFIGS. 5A and 5B, should be created.

Initially as a first step 701, Part B, which comprises a composition ofglue and water, should be poured into a mixing container of anappropriate size for the user's needs, dependent upon the measurementsof the surface area to be coated. Part B of the exposed aggregatearchitectural coating composition is a combination of glue and water, inthe amounts as depicted in FIGS. 5A and 5B. An exemplary embodiment canemploy the use of a very strong and durable glue material, such as“S-1100 Liquid Concentrate” polymer glue, in the Part B component. Inexemplary embodiments where the user desires to apply the exposedaggregate architectural coating to a flooring surface, Part B shouldcontain a ratio of three parts water to one part glue (ratio of 3:1), a“part” being any uniform measuring unit, e.g. pounds (lbs.) or quarts.In exemplary embodiments where the user desires to apply the exposedaggregate architectural coating to a wall surface, Part B should containa ratio of six parts water to one part glue (ratio of 6:1).

In exemplary embodiments, step 702 may be carried out, which wouldrequire that, if desired, an integral color pack or other suitablecement coloring method may be added to liquid Part A to change the colorof the architectural coating to any desired color, for aestheticpurposes, or can also be added during the mixing process as an optional“Part C” component. In exemplary embodiments, the user may lightly mixthe color pack or other coloring material with liquid Part B, in orderto break up any color pigment lumps within the color pack.

For step 703, Part A, which comprises a composition of sand and cement,should be prepared and then poured into the container having Part B. Theuser should determine which types of sand will be combined to form PartA. In exemplary embodiments, the user may combine multiple types of sandhaving various degrees of coarseness and various colors, in order tocreate an end result having a desired texture and design, once thearchitectural coating has been fully applied. Due to the architecturalcoating forming a thin layer of one-fourth of an inch or less upon anexisting concrete structure surface, a user may make more liberal use ofmore expensive sand and cement materials and finishes, such as usingwhite cement to create a white floor or wall surface.

In an exemplary embodiment, the proportions of sand to cement in Part A,as shown in FIGS. 5A and 5B, however, should be respected,notwithstanding use of various types of sand. Additionally, in exemplaryembodiments where the user seeks to create a coating having a thicknessof less than one-eighth of an inch, the user should not use a sandhaving a coarseness greater than United States Sieve Size No. 20, whichhas a size of 0.841 millimeters; otherwise, achieving the desiredthickness will typically not be possible. In other exemplary embodimentswhere the user desires to create a coating having one-eighth of an inchin thickness and up to one-fourth of an inch in thickness, a sandmaterial should not exceed a coarseness of United States Sieve Size No.16, which has a size of 1.19 millimeters; otherwise, achieving thedesired thickness will typically not be possible.

In an exemplary embodiment where the user seeks to create a coatinghaving a thickness of less than one-eighth of an inch, the user may use,for example, a combination of sand size no. 20, no. 30, and no. 60, toachieve a particular sand finish and texture. However, in otherexemplary embodiments where the user seeks to create a coating having athickness of less than one-eighth of an inch, the user should not use asand material having a coarseness of United States Sieve Size No. 16,which has a size of 1.19 millimeters, as this will prevent the user frombeing able to create a coating having the desired thickness of less thanone-eighth of an inch.

To illustrate various Part A compositions which can be employed inexemplary embodiments, three possible compositions will now bedescribed. In the first exemplary embodiment where the user desires tocreate an exposed aggregate architectural coating having a thickness ofless than one-eighth of an inch, the Part A composition may contain:eight pounds (lbs.) of Silica sand size no. 20, four pounds of Silicasand size no. 30, four pounds of Silica sand size no. 60, or maysubstitute another type of sand material, and sixteen pounds of cement,for a total of thirty-two pounds. Such a composition, while having aunique combination of silica sand types in order to meet creative anddesign needs, still respects the ratio of 14 parts sand to 16 partscement as depicted in FIGS. 5A and 5B where a coating having less thanone-eighth inch thickness is desired.

In similar exemplary embodiments, the amount of ingredients may beincreased, while maintaining the same ratio, such as to apply an exposedaggregate architectural coating to a larger surface area; for example,the same composition may combine 12.5 pounds of Silica sand size no. 20,6.25 pounds Silica sand size no. 30, 6.25 pounds of Silica sand size no.60, and 25 pounds of cement, for a total of fifty pounds.

Additionally, in such a composition the coarseness of sand should notexceed United States Sieve Size No. 20, which has a size of 0.841millimeters, in order to create the desired less than one-eighth inchthickness.

In the second exemplary embodiment where the user desires to create anexposed aggregate architectural coating having a thickness of one-eighthof an inch, the Part A composition may contain: eight pounds (lbs.) ofSilica sand size no. 16, four pounds of Silica sand size no. 20, fourpounds of Silica sand size no. 30, or may substitute another sandmaterial, and sixteen pounds of cement, for a total of thirty-twopounds. Such a composition, while having a unique combination of silicasand types in order to meet creative and design needs, still respectsthe ratio of 14 parts sand to 16 parts cement as depicted in FIGS. 5Aand 5B where a coating having a one-eighth inch thickness is desired.

In similar exemplary embodiments, the amount of ingredients may beincreased, while maintaining the same ratio, such as to apply an exposedaggregate architectural coating to a larger surface area; for example,the same composition may combine 12.5 pounds of Silica sand size no. 16,6.25 pounds Silica sand size no. 20, 6.25 pounds of Silica sand size no.30, and 25 pounds of cement, for a total of 50 pounds.

In the third exemplary embodiment where the user desires to create anexposed aggregate architectural coating having a thickness of one-fourthof an inch, the Part A composition may contain: eight pounds (lbs.) ofSilica sand size no. 16, four pounds of Silica sand size no. 20, fourpounds of Silica sand size no. 30, or may substitute another sandmaterial, and 20 pounds of cement, for a total of thirty-six pounds.Such a composition, while having a unique combination of silica sandtypes in order to meet creative and design needs, still respects theratio of 14 parts sand to 20 parts cement as depicted in FIGS. 5A and 5Bwhere a coating having a one-fourth inch thickness is desired.

In similar exemplary embodiments, the amount of ingredients may beincreased, while maintaining the same ratio, such as to apply an exposedaggregate architectural coating to a larger surface area; for example,the same composition may combine 11.11 pounds of Silica sand size no.16, 5.56 pounds Silica sand size no. 20, 5.56 pounds of Silica sand sizeno. 30, and 27.78 pounds of cement, for a total of approximately 50pounds.

If any materials have “settled” such that they are no longer uniformlymixed due to lengthy storage, these materials should first be stirred toa uniform consistency, such as with a “Jiffy” mixer, before being mixedwith any other material. For example, if the sand and cement have beenpreviously mixed and held in storage, the sand and cement may haveseparated and may need to be stirred first before being used to createthe Part A and Part B exposed aggregate architectural coatingcomposition.

If a stiffer consistency is desired for the architectural coating endresult, the amount of Part A liquid to be added to the composition canbe reduced. Conversely, if a more fluid consistency is desired, theamount of Part A liquid to be added into the composition can beincreased. The ratio of Part A to Part B liquid should not exceed 3.5 to6 quarts of Part A liquid per 50-pounds (lbs.) of Part B liquid.

The user then may slowly add Part A into the above mixing containerhaving Part B. To carry out step 704, the user may mix both partsthoroughly with a drill and paddle, such as a helical mixing paddle. Theuser may mix the components for three to five minutes until thecomposition is smooth and free of lumps or solid portions. A compositionthat has entrapped a large amount of air, e.g. having numerous airbubbles, may be mixed more thoroughly to remove the trapped air.

FIG. 8 depicts in detail the process for application of the exposedaggregate architectural coating to a flooring surface. FIG. 8 depictsmethod 800 for applying the exposed aggregate architectural coating to aflooring surface. Although method 800 is exemplarily shown with a seriesof steps in one particular sequence, method 800 may include fewer ormore steps in alternative sequences without deviating from the scope ofthe present invention. As will be described in greater detail below, theprocess of applying the exposed aggregate architectural coating to aflooring surface includes steps 801-808.

To carry out step 801, once the exposed aggregate architectural coatingcomposition has been prepared, where a thickness of less than one-eighthof an inch is desired, the exposed aggregate architectural coating canbe poured onto the surface to be coated, and can be spread using asqueegee, such as specifically an industrial floor squeegee having arubber blade. In exemplary embodiments where the user seeks to create acoating of less than one-eighth of an inch in thickness, the user canalternatively use a magic trowel to spread the coating to a desiredthickness, wherein the “Magic” trowel is similar to a squeegee having aflexible blade.

A desired exposed aggregate architectural coating thickness ofone-eighth of an inch requires that the poured coating is spread using agauge rake tool in the size of approximately 3/16″, where screeding (useof a floor screed, i.e. a commercial cementitious material combining aratio of cement and sand, can be employed as a smoothing and levelingaid if needed) and/or rodding (using a rod to smoothen the exposedaggregate architectural coating composition so as to create the desiredthickness) can also be employed, which will result in a #3 or #5 etchingdegree. A thickness of one-fourth of an inch requires application by agauge rake in the size of approximately 5/16″, where screeding and/orrodding can also be employed, which will result in an exposed aggregatefinish. Gauge raking, screeding, and rodding are all appropriate methodsfor applying and spreading the coating composition.

In an exemplary embodiment of the present invention, the user may wishto carry out step 802, in which the user may employ a broadcastingprocedure to create a customized exposed aggregate architectural coatingtexture, finish, and/or appearance, to meet creative and design needs.Immediately following the pour and spreading of the architecturalcoating material using either a squeegee, gauge rake, or other method,the user can perform the broadcasting procedure to broadcast aggregatematerials of various types into the exposed aggregate architecturalcoating. The materials to be broadcasted can include glass, sea shells,plastic including recycled plastic particles, or any other materialsuitable for decorative flooring or wall structures. In exemplaryembodiments, the aggregate materials to be broadcasted are applied ontop of the architectural coating immediately after the coating has beenapplied, and before the coating has dried. The aggregate materials arethen buried into the exposed aggregate architectural coatingcomposition, i.e. submerged into the exposed aggregate architecturalcoating such that the broadcasted aggregate materials are completelyencased by the exposed aggregate architectural coating, such that asmooth finish is created having an even and smooth top layer, but inwhich the aggregate materials having been broadcasted will still bevisible once the surface retarder and top layer of the exposed aggregatecoating have been removed.

Exemplary embodiments of the present invention result in anarchitectural coating having a thickness of one-fourth, or one-half ofan inch or less, as opposed to the industry-standard minimum of fourinches, resulting in the amount of broadcasted aggregate materialsapplied over the architectural coating being greatly reduced, furtherresulting in a much more cost-efficient surface-restoration process.Additionally, the amount of architectural coating required to bury thebroadcasted aggregates is also reduced, while still maintaining aconsistent exposed aggregate finish, as opposed to the industry-standardrequirement and practice, due to the exposed aggregate architecturalcoating being applied to form a thin layer that cannot result in thebroadcasted aggregates being buried to the point of invisibility. Thepresent invention is therefore much more cost-efficient than similarindustry-standard practices, employs a smaller quantity of materials,results in much less waste of materials, and employs an easierapplication method with a more aesthetically pleasing end result thansimilar industry-standard practices.

According to step 803, once the coating material has been evenly spreadto the desired thickness, having a uniform consistency as shown in FIG.1, and once the broadcasted aggregates (e.g. glass) have been applied ifdesired, the user should trowel the surface, such as by using avibrating trowel, in order to bring cement cream to the surface, and toremove any gauge or screed marks. The user should vibrating trowel thesurface, e.g. using a “Fresno” vibrating trowel, or can also employeeuse of a standard trowel, such that the coating layer is as smooth aspossible, leaving minimal trowel marks. If troweling is exceedinglydifficult due to the stickiness of the glue, the user may apply a watermist as a layer between the architectural coating and the trowel, suchthat the trowel may glide over the coating more easily. The user may optto trowel the coated surface a second time, and even a third time,depending on the desired surface texture and finish.

The user can, in addition or alternatively, in accordance with step 804,apply a weighted trowel, such as a weighted “Fresno” trowel, to theentire coated surface, using a minimum of two weights, in order toremove any trowel marks from the initial trowel passes, and to create auniformly smooth surface. The user should ensure that no trowel marksare left after this final weighted trowel pass. Other suitable trowelingtechniques may also be utilized to facilitate the creation of a uniformsmooth surface. Water can be lightly misted onto the coated surface, asa finishing aid. If the user has elected to broadcast aggregatematerials, e.g. glass, into the exposed aggregate architectural coating,the user should be sure not to damage the broadcasted aggregates duringthe troweling process.

The user may perform a finger-print test to determine if the coatingmaterial has cured, by touching the coated surface with one finger. Ifonly fingerprints are left behind and the coated surface cannot bedepressed, the user can then perform step 805 of applying a surfaceretarder. (Alternatively, in one exemplary embodiment, the user maychoose not to apply a surface retarder to the coated surface, to producea smoother, light-exposed aggregate coated surface. If no surfaceretarder is used, the exposed aggregate architectural coating shouldnonetheless be left to cure for twenty-four hours.) It is important thatthe surface retarder is not applied until the exposed aggregatearchitectural coating has cured, as determined by the above-describedfingerprint test. This fingerprint test method for determining if acement surface has cured is unique to the present invention; whiletypically those skilled in the art determine if a cement surface coatinghas cured simply by observing the appearance of the coating, afingerprint test is utilized here, because of the uniqueness of theappearance and texture of the exposed aggregate architectural coatingmaterial.

Once the user has employed the fingerprint test to determine that thecoating has cured, the user can then apply a chemical surface retarderto the coated surface as per step 805, uniformly covering the entirearchitectural coating with the surface retarder. The user can apply theuser's preferred surface retarder, at the desired finish (in exemplaryembodiments, retarder #1, #3, or #5 can be used for a sanded finish, andretarder #15 or greater should be used for an exposed aggregate finish).The user should be sure to cover the entire coated surface with thesurface retarder. If during the application of the surface retarder,areas of the coating have dried faster than others, the user may employan “acid-washing” technique using etching material or detergents to etchthe coating that has dried to ensure that all areas of the coating areuniform in consistency. Alternatively and in other embodiments, etchingmaterial can be utilized throughout the application process to create aconsistent finish and exposure.

To perform step 806, the chemical surface retarder should be left tocure on the coated surface for twenty-four hours. The user should allowthe coating material with the applied surface retarder to stiffen andcure over time, typically for twenty-four hours. (When performing asqueegee application such that a light acid-wash finish is desired, theuser should allow the coating material to stiffen and cure for a minimumof twenty-four hours).

To perform step 807, in exemplary embodiments, the user may then washoff the surface retarder after twenty-four hours have elapsed, such asby utilizing a pressure washer with a rotary surface cleaner attachment.After at least twenty-four hours have elapsed and the desired finish hasbeen attained, the user may pressure-wash the newly coated surface tothe desired uniform finish, removing any cement residue or laitance,using etching material if needed to clean the surface thoroughly; theuser may also employee laitance washing as needed. Other suitabletechniques for removal of the surface retarder may be utilized to removethe surface retarder after twenty-four hours have elapsed since itsapplication.

The user should then wait another twenty-four hours after the surfacehas been pressure-washed. The user then should employee “acid-washing”to the coated surface using etching material and/or detergents. In anexemplary embodiment, the user can apply etching material to create alight acid-wash finish if desired. In an exemplary embodiment, after thesurface retarder has been removed, or if the user has elected not toapply a surface retarder, the user can etch the newly-coated surface toa desired texture, such as by acid-washing or chemically etching thesmooth surface. If the user has elected to apply a surface retarder,then a minimum of twenty-four hours should elapse, after which theremaining cement residue or laitance can be removed, such as byacid-washing or by chemically etching the surface. The resultantarchitectural coating will result in a durable, consistent exposedaggregate finish, having a thickness of less than one-fourth of an inch.

Additionally, in an exemplary embodiment of the present invention, theuser may seal the architectural coating using a manufactured sealant,following the manufacturer's instructions and recommendations for use ofthe sealant. In exemplary embodiments where the exposed aggregatearchitectural coating has been applied indoors, the user may also use apolishing machine on the exposed aggregate architecturally coatedsurface to create a smooth finish resembling the material of polishedconcrete and/or terrazzo.

FIG. 9 depicts in detail the process for application of the exposedaggregate architectural coating surface to a wall surface. FIG. 9depicts method 900 for applying the exposed aggregate architecturalcoating to a wall surface. Although method 900 is exemplarily shown witha series of steps in one particular sequence, method 900 may includefewer or more steps in alternative sequences without deviating from thescope of the present invention. As will be described in greater detailbelow, the process of applying the exposed aggregate architecturalcoating to a wall surface includes steps 901-908.

The process of applying the exposed aggregate architectural coating to awall surface will be similar to the process of application for aflooring surface. The wall surface should first be prepared androughened in accordance with the method outlined in FIG. 6, just as isdone when the coating is to be applied to a flooring surface. However,unlike the procedure for coating a flooring surface, here the usershould carry out step 901 of applying the exposed aggregatearchitectural coating material to the desired thickness using the spraymethod. In exemplary embodiments, using the spray method to apply thearchitectural coating may be desired, so that the applied coating has auniform consistency throughout, and is not over-applied in some areasand under-applied in others. Where the desired coating thickness isthinner, such as in exemplary embodiments where a one-eighth inchthickness is desired, it will be particularly beneficial to use thespray method, as achieving a thin coating by another method is likely tobe challenging. When applying the coating to a wall surface, step 902necessitates use of the float method, used to create a uniformly flatsurface for a wall coating, which typically involves use of a levelingcement mortar applied according to the manufacturer's specifications.

The remaining procedure for application of the coating to a wall surfacewill resemble the flooring application procedure. For step 903, afterthe float method has been employed, the user may then trowel the entirecoated surface to create a smooth finish. To perform step 904, theexposed aggregate architectural coating should be left to cure andharden for twenty-four hours. If desired, prior to leaving the exposedaggregate architectural coating to cure and harden for twenty-fourhours, the fingerprint test described above may be employed to ensurethat the coating has adequately hardened, and if so, then a surfaceretarder may be applied. The surface retarder may be applied accordingto the manufacturer's specifications, and according to the user'sdesired surface texture.

After yet another twenty-four hours have elapsed, the user may performstep 906, in which the surface retarder is washed away using apressure-wash, and the coated surface is then “acid-washed” usingetching material and/or detergents to remove cement residue and laitanceand create a desired texture; laitance washing therefore can also beemployed as necessary. In exemplary embodiments, according to the user'spreference, the user may apply a commercial sealant to the coatedsurface according to the manufacturer's specifications. In exemplaryembodiments where the exposed aggregate architectural coating has beenapplied indoors, the user may also use a polishing machine on theexposed aggregate architecturally coated surface to create a smoothfinish resembling the material of polished concrete and/or terrazzo.

Weather conditions may affect the installation of the exposed aggregatearchitectural coating. Hot weather, such as environmental temperaturesabove 75° F. (23° C.), may speed up the time in which the coating iscured. Therefore, when hot weather conditions are anticipated duringapplication of the architectural coating, the user should keep thecoating material cool by using chilled water when preparing the initialPart A and Part B exposed aggregate architectural coating composition.The user also should follow American Concrete Institute (“ACI”)Committee publication 305, “Specification for Hot Weather Concreting.”

Conversely, cold weather conditions will also affect the installation ofthe exposed aggregate architectural coating. Environmental temperaturesbelow 60° F. (15° C.) may delay the setting time and thereby requirelonger than twenty-four hours for the coating to fully cure. In suchconditions, the user may need to reduce the surface retarder strength,or wash the coating without a rotary attachment. In such cold weatherconditions, the user should attempt to keep the architectural coatingmaterial warm, by using heated water when preparing the initial Part Aand Part B exposed aggregate architectural coating composition. The useralso should follow American Concrete Institute (“ACI”) Committeepublication 306, “Guide to Cold Weather Concreting.”

Generally, the exposed aggregate architectural coating material shouldbe applied only when surface temperatures are above 55° F. and rising,and not expected to exceed 100° F. Furthermore, the coating should notbe applied when precipitation is expected to occur within twenty-fourhours following completion of the application. If the exposed aggregatearchitectural coating part A and part B have been separately mixed andplaced in storage for use at a later date, the user should not allow theexposed aggregate architectural coating material to freeze duringstorage. Once part A and part B are mixed together, the mixture willbegin to harden immediately, and therefore should be applied to apre-existing concrete structure surface immediately. Part A and part Bof the exposed aggregate architectural coating, when pre-mixedseparately and stored for later use, each have a shelf life of twelvemonths when stored in a dry location, protected from moisture, fromdirect sunlight, and stored in an undamaged, uncompromised storagecontainer.

The foregoing detailed description has set forth various embodiments ofthe system and/or methods by the use of diagrams, flowcharts, and/orexamples. Insofar as such diagrams, flowcharts, and/or examples containone or more functions and/or operations, it will be understood by thosewithin the art that each function and/or operation within such diagrams,flowcharts, or examples may be implemented, individually and/orcollectively, by a wide range of materials, compositions, methods,techniques, or virtually any combination thereof.

Those skilled in the art will recognize that it is common within the artto describe systems and/or methods in the fashion set forth herein, andthereafter use engineering practices to integrate such described systemsand/or methods into other similar systems. That is, at least a part ofthe systems and/or methods described herein may be integrated into acement-based coating system and/or method via a reasonable amount ofexperimentation.

The subject matter described herein sometimes illustrates differentcomponents contained within, or connected with, other components. It isto be understood that such depicted architectures are merely exemplary,and that in fact many other architectures may be implemented whichachieve the same functionality. In a conceptual sense, any arrangementof components to achieve the same functionality is effectively“associated” such that the desired functionality is achieved. Hence, anytwo components herein combined to achieve a particular functionality maybe seen as “associated with” each other such that the desiredfunctionality is achieved, irrespective of architectures or intermediatecomponents.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art may translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for thesake of clarity.

A system and method for an exposed aggregate architectural coating hasbeen described. The foregoing description of the various exemplaryembodiments of the invention has been presented for the purposes ofillustration and disclosure. It is not intended to be exhaustive or tolimit the invention to the precise form disclosed. Many modificationsand variations are possible in light of the above teaching withoutdeparting from the spirit of the invention.

1. A method for preparing and applying an exposed aggregatearchitectural coating, comprising: preparing a first composition bycombining 41 to 50 percent sand with 50 to 59 percent cement; preparinga second composition by combining 75 to 86 percent water with 14 to 25percent glue; combining the first composition with the secondcomposition to form an exposed aggregate architectural coating;preparing a pre-existing cement structure to create a roughened surfacehaving a concrete surface profile of three or greater; and applying theexposed aggregate architectural coating to the roughened surface of thepre-existing cement structure by evenly spreading the exposed aggregatearchitectural coating onto the roughened surface to create an eventhickness of the exposed aggregate architectural coating, wherein theexposed aggregate architectural coating forms a thickness of between1/32nd of an inch and one-fourth of an inch above the roughened surface,wherein combining the first composition with the second composition toform the exposed aggregate architectural coating occurs prior toapplying the exposed aggregate architectural coating to the roughenedsurface of the pre-existing cement structure.
 2. The method of claim 1,wherein the first composition of the exposed aggregate architecturalcoating is comprised of 47 percent sand and 53 percent cement.
 3. Themethod of claim 1, wherein the first composition of the exposedaggregate architectural coating is comprised of 41 percent sand and 59percent cement.
 4. The method of claim 1, wherein roughening thepre-existing cement structure to create the roughened surface respectsany pre-existing structures within the pre-existing cement structure. 5.The method of claim 1, wherein applying the exposed aggregatearchitectural coating to the roughened surface of the pre-existingcement structure is achieved by spreading the exposed aggregatearchitectural coating to a desired thickness using a gauge rake method,a squeegee method, a spray method, a screeding method, a rodding method,or a combination thereof.
 6. The method of claim 5, wherein applying theexposed aggregate architectural coating to the roughened surface of thepre-existing cement structure is further achieved by troweling theexposed aggregate architectural coating after it has been spread to thedesired thickness, such that the exposed aggregate architectural coatinghas a smooth and uniform consistency.
 7. The method of claim 1, whereinapplying the exposed aggregate architectural coating to the roughenedsurface of the pre-existing cement structure further includesbroadcasting aggregates to the exposed aggregate architectural coatingto create a customized exposed aggregate architectural coatingappearance.
 8. A method for preparing and applying an exposed aggregatearchitectural coating to a flooring surface, comprising: preparing afirst composition by combining 41 to 50 percent sand with 50 to 59percent cement; preparing a second composition by combining 75 percentwater with 25 percent glue; combining the first composition with thesecond composition to form an exposed aggregate architectural coating;preparing a pre-existing cement structure to create a roughened surfacehaving a concrete surface profile of three or greater; and applying theexposed aggregate architectural coating to the roughened surface of thepre-existing cement structure by evenly spreading the exposed aggregatearchitectural coating onto the roughened surface to create an eventhickness of the exposed aggregate architectural coating, wherein theexposed aggregate architectural coating forms a thickness of between1/32nd of an inch and one-fourth of an inch, wherein combining the firstcomposition with the second composition to form the exposed aggregatearchitectural coating occurs prior to applying the exposed aggregatearchitectural coating to the roughened surface of the pre-existingcement structure.
 9. The method of claim 8, wherein the firstcomposition of the exposed aggregate architectural coating is comprisedof 47 percent sand and 53 percent cement.
 10. The method of claim 8,wherein the first composition of the exposed aggregate architecturalcoating is comprised of 41 percent sand and 59 percent cement.
 11. Themethod of claim 8, wherein roughening the pre-existing cement structureto create the roughened surface respects any pre-existing structureswithin the pre-existing cement structure.
 12. The method of claim 8,wherein applying the exposed aggregate architectural coating to theroughened surface of the pre-existing cement structure is achieved byspreading the exposed aggregate architectural coating to a desiredthickness using a gauge rake method, a squeegee method, a spray method,a screeding method, a rodding method, or a combination thereof.
 13. Themethod of claim 12, wherein applying the exposed aggregate architecturalcoating to the roughened surface of the pre-existing cement structure isfurther achieved by troweling the exposed aggregate architecturalcoating after it has been spread to the desired thickness, such that theexposed aggregate architectural coating has a smooth and uniformconsistency.
 14. The method of claim 8, wherein applying the exposedaggregate architectural coating to the roughened surface of thepre-existing cement structure further includes broadcasting aggregatesto the exposed aggregate architectural coating to create a customizedexposed aggregate architectural coating appearance.
 15. A method forpreparing and applying an exposed aggregate architectural coating to awall surface, comprising: preparing a first composition by combining 41to 50 percent sand with 50 to 59 percent cement; preparing a secondcomposition by combining 86 percent water with 14 percent glue;combining the first composition with the second composition to form anexposed aggregate architectural coating; preparing a pre-existing cementstructure to create a roughened surface having a concrete surfaceprofile of three or greater; and applying the exposed aggregatearchitectural coating to the roughened surface of the pre-existingcement structure by evenly spreading the exposed aggregate architecturalcoating onto the roughened surface to create an even thickness of theexposed aggregate architectural coating, wherein the exposed aggregatearchitectural coating forms a thickness of between 1/32nd of an inch andone-fourth of an inch, wherein combining the first composition with thesecond composition to form the exposed aggregate architectural coatingoccurs prior to applying the exposed aggregate architectural coating tothe roughened surface of the pre-existing cement structure.
 16. Themethod of claim 15, wherein the first composition of the exposedaggregate architectural coating is comprised of 47 percent sand and 53percent cement.
 17. The method of claim 15, wherein the firstcomposition of the exposed aggregate architectural coating is comprisedof 41 percent sand and 59 percent cement.
 18. The method of claim 15,wherein roughening the pre-existing cement structure to create theroughened surface respects any pre-existing structures within thepre-existing cement structure.
 19. The method of claim 15, whereinapplying the exposed aggregate architectural coating to the roughenedsurface of the pre-existing cement structure is achieved by spreadingthe exposed aggregate architectural coating to a desired thickness usinga gauge rake method, a squeegee method, a spray method, a screedingmethod, a rodding method, or a combination thereof.
 20. The method ofclaim 19, wherein applying the exposed aggregate architectural coatingto the roughened surface of the pre-existing cement structure is furtherachieved by troweling the exposed aggregate architectural coating afterit has been spread to the desired thickness, such that the exposedaggregate architectural coating has a smooth and uniform consistency.